Types of Welding in Industry: Everything You Need to Know

Joining metal components affects the strength of the product, the finish level, manufacturing speed, and additional parameters. Sometimes rapid welding is required to run production series without interruptions, and in other cases welding with precision of tenths of a millimeter and a clean finish is required.

In order to choose a suitable welding method, it is important to be familiar with the different options and distinguish between them.

The Importance of Welding Processes in Industry

Welding enables the creation of permanent joints between metal parts using heat, pressure, or a combination of both. Welding processes create a strong joint, even stronger than the material itself. Welding is used in every industrial sector, from vehicle manufacturing to construction of buildings and infrastructure.

Different types of welding affect the joint strength, finish appearance, and manufacturing cost in different ways. Each welding method is suitable for different metals, dimensions, and requirements.

MIG Welding: A Common Method on Production Lines

MIG welding (short for Metal Inert Gas) is performed by feeding a continuous metal wire as filler material and using a gas that prevents oxidation in the welding zone. The gas typically consists of a mixture of argon and carbon dioxide.

The metal wire is inserted between the metal components to be joined using a welding gun. It is possible to control the angle, distance, and speed of welding, weld in various positions, and adjust the working parameters to the type of material and thickness.

MIG welding is relatively easy to learn and operate, and is suitable for application in large-scale manufacturing processes. MIG welding is performed quickly and enables continuous joining of steel, stainless steel, and aluminum parts in various thicknesses. On industrial production lines, MIG welding is usually the method of choice, especially when the goal is to manufacture quickly.

Advantages of MIG welding:

• High working speed and continuous production
• Compatibility with a variety of metal types and thicknesses
• A relatively easy method to learn and implement
• Ideal for large-scale serial production

TIG Welding: High Finish Quality

TIG welding (short for Tungsten Inert Gas) is performed using a non-consumable tungsten electrode and argon gas that serves as a shield. The filler material is fed manually by the welder. This is a welding method that allows precise control of heat and the amount of filler material, and therefore provides results with a high level of precision.

TIG welding is suitable for projects requiring a high level of precision and a meticulous aesthetic result, and is therefore common in manufacturing processes for sensitive industries such as medical or aerospace. A wide variety of metals can be welded using this method, including stainless steel, titanium, and thin aluminum.

It should be taken into account that TIG welding is slower compared to MIG welding and requires a high level of skill from the operator. The welder needs to hold the welding gun in one hand and the filler rod in the other, and control both hands simultaneously. Therefore, TIG welding is not suitable for large-scale serial production, but rather for projects where quality takes precedence over speed.

Electrode Welding: A Veteran and Versatile Method

SMAW / MMA welding is performed using a coated electrode that is consumed during the welding process. The coating creates gas and a slag layer that protect the joint area from oxidation. Afterwards, the welder cleans the slag layer to expose the weld seam.

Electrode welding is a veteran method still in widespread use, mainly in field conditions since it does not require an external gas tank or complex equipment. Metals of significant thickness can be welded using an electrode for maintenance work, construction, and repairs.

On the other hand, electrode welding also has a notable disadvantage: the finish is less smooth than in TIG or MIG welding.

When to use electrode welding:

• Field work without access to shielding gas
• Repairs and maintenance of existing structures
• Thick materials requiring deep penetration

How to Choose the Right Type of Welding?

The welding method for joining metal parts should be chosen based on several factors. First, the choice is made according to the type of metal to be processed. Aluminum requires a different welding approach compared to carbon steel, stainless steel requires welding with a clean finish without heat stains, and so on.

Another significant factor is the thickness of the metal. Thin materials require precise heat control to prevent distortion or burn-through, whereas thick materials require the application of higher energy.

Based on the manufacturing requirements in terms of strength and precision, one determines whether to use precise TIG welding or fast MIG welding.

Working conditions should also be considered. In a controlled factory environment, MIG or TIG welding methods work excellently. In open field conditions, electrode welding is preferable because it is not affected by weather conditions.

Finally, production volume and regulatory standards are additional factors that help determine how to weld parts for a project.

Welding as Part of a Broader Manufacturing Process

In industry, welding is usually one stage within an overall manufacturing setup. Before the welding stage, preliminary processes are performed such as laser cutting of raw materials or shaping and bending of metal components according to an engineering drawing. Each stage in the process affects the next one.

The quality of metal cutting and bending directly affects the quality of welding. Parts that were cut with high precision connect better and require less finishing work after welding. Straight and clean edges enable good penetration of the filler material and create a strong joint.

It is important to plan all manufacturing stages carefully in order to reduce waste, errors, and costs. The likelihood of achieving a high-quality end product that meets requirements is higher when the cutting, bending, and welding of parts are planned in advance. Factories that work with a single supplier for all manufacturing stages benefit from better coordination and experience fewer problems.

Admati Agencies – Manufacturing Processes for Industry

At Admati Agencies, we provide manufacturing solutions and components for advanced industries, such as sheet metal bending that enables precise production welding further down the line. The extensive experience we have accumulated working with diverse clients in Israel and worldwide allows us to tailor the manufacturing process to the requirements of each project. Contact us for professional consultation according to your project needs.

Questions and Answers About Types of Welding

What is the difference between MIG welding and TIG welding?

MIG welding uses a continuous metal wire. This is a faster welding method, suitable for serial production. TIG welding uses a tungsten electrode. This method allows greater precision and provides a clean finish.

Which type of welding is suitable for aluminum?

Aluminum can be welded using both MIG and TIG. TIG welding is preferred when there is a requirement for precision and quality over speed.

Is electrode welding still in use?

Yes. Electrode welding is common in field conditions, construction work, and maintenance. This welding method does not require an external gas tank. On industrial production lines, it is less common because MIG and TIG provide better results.

How does welding affect the joint strength between metal components?

Welding quality directly affects the joint strength between metal parts. Quality welding creates a joint as strong as the material itself or even stronger. Poor quality work can lead to defects such as cracks, porosity, or simply a joint that is not strong, stable, and durable enough.

Are there standards for welding in industry?

Yes. AWS and ISO 3834 standards define quality requirements for welding processes. In sensitive industries such as semiconductors or medical devices, compliance with standards and full documentation of manufacturing processes are essential requirements.